Overmolded Battery Fastener for Grounding Composite Enclosures
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Solution Overview
Problem
Large battery packs for vehicles pose challenges due to their size, leading to increased enclosure weight and difficulty in grounding the battery, especially when using non-conductive composite materials.
Innovation Solution
An electrically conductive stud is overmolded into the battery enclosure, extending from the interior to the exterior to provide an electrical grounding path, thus enabling the use of non or less electrically conductive composite materials for the enclosure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If non-conductive composite materials are used for the battery enclosure, then the enclosure weight is reduced, but the ability to provide electrical grounding is lost
Solution Approach 1:
The enclosure is segmented into non-conductive composite material sections for weight reduction, while separate conductive fastening system sections provide the necessary electrical grounding paths. This segmentation allows each material to perform its optimal function without compromising overall system requirements.
Solution Approach 2:
The solution employs composite construction by combining non-conductive composite materials (for weight reduction) with conductive metal components (for grounding). The fastening system integrates metal studs and bolts that extend through the composite enclosure to establish electrical grounding paths to the vehicle chassis.
2Quantity of substance
If the battery pack size is increased to meet energy demands, then the power capacity is improved, but the enclosure weight increases substantially
Solution Approach 1:
The enclosure utilizes composite materials that provide high strength-to-weight ratios, allowing the enclosure to scale with larger battery capacities without proportionally increasing weight. The composite construction maintains structural integrity while minimizing mass addition.
3Reliability
If conductive metal enclosures are used, then electrical grounding is achieved, but the weight of the enclosure increases
Solution Approach 1:
The enclosure system is segmented into non-conductive composite panels for the main enclosure body and separate conductive fastening components for grounding. This segmentation allows the majority of the enclosure to be lightweight composite material while only the necessary fastening elements provide electrical conductivity for grounding.
4Weight of moving object
If composite materials are used for the enclosure, then weight is reduced, but the difficulty of grounding the battery increases
Solution Approach 1:
The fastening system is designed with pre-configured conductive paths through the composite enclosure. The metal studs are overmolded into the composite material during manufacturing, establishing grounding paths in advance before the enclosure is assembled and installed in the vehicle.
Solution Approach 2:
The conductive metal fastening components are nested within or integrated into the non-conductive composite enclosure structure. The metal studs are embedded in the composite material, creating a hierarchical structure where the conductive elements are contained within the composite matrix, providing grounding while maintaining the lightweight composite construction.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides structural integrity to the enclosure and ensures electrical grounding for the battery, maintaining the enclosure's sealing capability while distributing mechanical forces to alleviate localized stress.
Implementation Method 1
an electrically conductive stud overmolded into an enclosure, the electrically conductive stud extending from an interior of the enclosure to an exterior of the enclosure to provide an electrical grounding path through the enclosure
Implementation Method 2
an electrically conductive stud overmolded into an enclosure
Implementation Method 3
an outer portion of the fastening system includes threaded surfaces, enables mechanical fastening of the enclosure when engaged with a nut
Implementation Method 4
An overall configuration of the fastening system, and interfacing of the fastening system with the enclosure, promotes distribution of mechanical forces to alleviate localized stress imposed on the enclosure when the enclosure is assembled and sealed
Data Source
AI summary
A method and system are provided for a fastening system comprising: an electrically conductive continuous unitary structure, such as an electrically conductive stud, overmolded into an enclosure, the electrically conductive stud extending from an interior of the enclosure to an exterior of the enclosure. The fastening system may act as a structural member transferring mechanical forces away from the battery enclosure, secure the battery enclosure to a mount, aid in sealing the battery enclosure, and act as an electrical grounding path for the battery through an enclosure formed of a non-electrically conductive composite material.